Art of making faced cementitious products



A. 0. CROZIER. ART OF MAKING FACED CEMENTITIOUS PRODUCTS. APPLICATION FILED JUNE 14, 1918- RENEWED JULY 21, I920.

Patented Apr 26, 1921. 3 SHEETSSHEET 1.

0 alaAiiorney L ED JUNE 14, NHL RENEWEDJULY 21, I920.

Patented Apr. 25, 1921.

3 SHEETS-SHEET 2.

eye W A. 0. CROZIE'R. ART OF MAKING FACED CEMENTITIOUS PRODUCTS. ,APPLICATION FILED JUNE 4 IQIB- RENEWED JULY 21,1920- 1,376,321. Patented Apr. 26, 1921.

UNITED STATES- PATENT orn-ca.

ALFRED OWEN CROZIER, OF NEW YORK, N. Y.

.an'r or ma a racnn omrmzrrrxoos rnonoc'rs.

. Specification of Letters Patent.

Patented Apr. 26, 1921.

Application filed June 14, 1918, Serial K0. 239,926. B-enewed July 21, 1920. Serial No. 398,044.

To (ZZZ whom it may concern:

' ferentin consistency, composition, or color,

etc. and the chief object of the invention is to provide a simple, effective and economical iethod for the purpose. To this and other ends the invention consists in the novel procedure hereinafter described.

Various steps in the preferred mode of practising the invention are illustrated in the accompanying drawings. in which are also shown. somewhat diagrammatically, certain parts of the apparatus which Ipre t'cr to employ.

Referring to the drawings:

Figure l is arear view. partlv in vertical cross-section. of the upright hollow shaft,

or container in which is established and maintained a cenicntitious column of slushy concrete.

Fig. 2 is a section about in line of Fig. 1. showing also the knives by which the lower portion of the cementitious column is' severed and divided. and the removablepallet or closure. with a facing layer there on. in position at the bottom of the shaft or container. 1

Fig. 3 is'a sectional plan view on line 3-3 of Fig. 2. 1

Fig. r is a section similar to Fig. 2 but showing a method of introducing a layer of facing material into the shaft or container at one side of the same.

Fig. 5 is a horizontal section on a plane corresponding to line 5-5 of Fig. r. showing the arrangement when a facing layer is to be provided on two continguous sides of the cementitious product or products.

Fin. 6 is an end view of a pallet .with a layer of facing material thereon.

Fig. 7 is a perspective view of a pallet load of faced brick.

Fig. 8 is a perspective view of a faced block, on the'pallet on which it is formed.

1g. 9 a perspective view showing 21 facing layer on a piece of woven fabric to give a corresponding texture to the facing. F 1g. 10 is a perspective View showing a pallet loadofbrick faced on the u per side. Fig. 11 is a perspective view s owing a fabric on top 0 a suitably supported block to impart to the surface of the latter a corres onding texture.

ig. 12 is a perspective view of a brick or block faced on one side and on an ad joining end.

Fig. 13 is a perspective view illustratinga simple and convenient method of forming a facing layer on a pallet. Fig. let 1s a perspective view illustriting a simple and effective way of applyinga facing layer on the upper surface of ablock or other product.

Fig. l5is a side View, partly in section,- illustratmg a method of imparting a rock like surface or other. finish to the biocks or bricks. p In carrying out iny invention in the preferred manner I employ an upright hollow shaft or container 15, closed at the bottom by a removable pallet 16 resting on a table.

17 which can be raised and lowered by means of any convenient-and suitable mechanism. not shown. In the lower. part of the shaft, at a suitable distance above the pallet, ac-

cording to the thickness of the products which are to be made, the front and rear walls of the shaft are provided with horizontal slots 18, 19, to receive a horizontal knife 20, and with vertical slots ZLQQ, to

receive vertical knives The knives men 5 tioned are by preference rigidly connected together, and are reciprocated at the proper times by suitable means. not shown. The shaft preferably has an upward taper, as indicated. at least above the horizontal slots. Preferablythe front and rear walls of the part below the slot are parallel but the side walls are slightly inclined though to a less extent than the side walls above the slots.

The shaft 15 is filled 'iio a suitable height, as will be explained hereinafter) with slush concrete. that is, a mixture containing a cementitions ingredient. sand or other suitable material, and water in excess. preferably considerably in excess, of that re,-

lit)

quired for complete hydration of the cem entitious ingredient. The lower portion of the column thus formed is subjected to a marked unwatering and compacting or densifying effect by the weight of the mass above, the water, being lighter, gradually finding its way upwardly. The effect is more or less proportional to the height of the column, and in practice the column is maintained preferably at such a height that the unset products carved or shaped from the said lowe1"portion are unwatered and compacted enough to make them self-sustaining without lateral support. Forcing the knives 20 and 23, of substantial thickness, into the column produces a further compacting of the lower portion. as will be readily understood.

The primary function of the horizontal knife 20 is to sever from the column the compacted and nnwatered portion below the slots 18, 19, which portion is then divided into bricks or smaller blocks by the vertical knives 23. These operations having been performed the knives are retracted until the vertical knives are entirely withdrawn, but leaving the horizontal knife in the column. The table 17 and ballet l6. with the severed and divided portion of the column. are now lowered. leaving the upper part of the column resting on the knife 20: the pallet is removed with its load of bricks and carried away to a place Where the bricks may bedeft to set and harden, a fresh pallet is placed on the table. and the latter is raised to bring the fresh pallet into position at the bottom of the shaft.

The horizontal knife 20 is then withdrawn, preferably as quickly as possible, whereupon the upper part of the column drops bodily upon the pallet, the violent impact thus produced aiding materially in compacting of the lower part of the column; and the shaft being tapered. the sudden descent of the column tends to open cracks or spaces .at' the sides of the shaft. into which excess water is sucked and is expelled upwardly. thus aiding in the un atering of the column.

As the operations described are repeated, the column is maintained at the proper height by supplying fresh cemcntitions material of suitable consistency at the top, eitlier continuously or at such intervals as may be most convenient or desirable under the prevailing conditions.

The concrete in the lower portion of the column. though unwatcred. is nevertheless wet concrete: that is. it contains ample water for hydration of the cementitious ingredient. and is therefore to be distinguished from the dry concrete use in so-called dry processes of making concrete blocks and other articles.

lVith a given shaft 15. the number and size of the products formed depend upon the in Figs. 2. 6, 7 and 13. For this purpose a.

shallow frame 2- which may be of sheet .metal, is provided. to fit down upon the pallet 16. as shown in Fig. 13. The opening in the frame (Avhich opening is of the same size as the inside of the bottom of the shaft 15) is filled with the facing material, which may be of any suitable consistency, but preferably more or less slushy. The frame is then removed. leaving on the pallet a layer or relatively thin body of facing'material 25, Fig. 6. and the pallet is placed in position at the bottom of the shaft, as shown in Fig. 2. Then when the horizontal knife 20 is withdrawn, the upper part of the column, which was supported by the knife, drops bodily upon the facinglayer so that the two are integrally joined. any air between the two is driven out. and the facing layer is compacted. or densified, and unwatered. after which the now faced lower portion of the column is severed therefrom and, if desired. divided into smaller blocks, or bricks. Fig. 7 shows a pallet load of faced brick. and Fig. 8 a single faced block produced in this way. The material for the facing layer can be quite wet. being preferably just thick enough to keep from spreading until the pallet is placed under the shaft. Then the heavy impact of the column. when the horizontal knife is withdrawn. and the subsequent pressure exerted by the introduction of the knife or knives. thoroughly compact or densify. or stabilize. the layer so that it will sustain the weight of the block or bricks while hardening.

Another scheme is illustrated in Figs. 10 and 14. In this case the facing layer on the pallet is omitted and the vertical knives 23 are not used. \Vhen the pallet is removed from the bottonf of the shafta frame 26. Fig, 14. is set down around the block 27. the frame being slightly higher than the block. The facing'material 28 is then deposited on the upper face of the block and leveled off to the top of the frame. after which. if deproper distance therefrom by means of pins 80, and extending well duwn toward the pad: of the knife- 20. lnt'oithe space thus provided between the plate and the adje cent wall the facing material 29 is supplied at a rate to keep pace with the severance of blocks or bricks from the bottom of the, column. This facing material can be quite. soft. Below the plate the column and the, layer of facing material join, as indicated in Fig. l, and-are, integrally united by the lateral pressure ofthe former. To avoid all possibility'of rupture of the facing layer and consequent spreading of the colunm through the layer to the shaft wall at the point of upture, thereby producing an imperfect or defective. facing, the plate is preferably forced down or allowed to -fall with the column as the latter descends and then drawn u again before or after the knife is. re-introc uced into the column to sever the next block therefrom. In'tiiis way a-laycr of facing material is carried down the side of the shaftapd applied'to the sideof the column therein, producing afacing on that side of the products which are cut fromthe bottom of the column. Vertical knives-23 eref not shown in Fig. at, but it is to be understood that they may be used if desired. it lfacin s are desired on other sides also, additional plates are employed in the column, as for example the plate 31, Fig. In this way all four sides of the block can be faced. At the same time the scheme illustrated in Figs. 2 and 13 may be used, to provide a facing on another face of the block, and the remaining surface can be faced by the method illustrated in Fig. 14. In this way as many surfaces as desired can be faced. Fig. 12 shows a block or brick faced onjoneend and one side.

The facings can. be given a surface design or texture in various ways. For example pallet 16 can be covered with a piece of woven fabric 32' and the facing layer 25 formed thereon, as shown in Fig. 9, in the manner already described in connection with Fig. 13. Then when the column in the shaft 15 descends upon the fming layer the pattern of the fabric is impressed upon the facing. The fabric can be left in place until the material has hardened, or the block can be turned over upon another supporting surface and the fabric peeled oil at once. Another way is to apply the facing by the. method illusti'ated in Fig. 14 and then to apply the fabric on top, as indicated at 33 in Fig. ll, pressing the fabric down upon the more or less yielding mass by means of a roller or otherwise. The fabric is then stripped 0E and the block set aside to harden.

A finish which for many purposes is highly pleasing anddesirable can be given to one onmore faces of the blocks or other products by the method illustrated in Fig. 15.. For this purpose the block,'brick, or other article, rest on the pallet 16 on which it was forme or turned over upon another allet or other suitable support, is inclose'd m a. lateral support, such as a close fitting open frame or box 34 and over the surface of ti block (which may or may not have a fax zing layer 35) is strewn sand, crushed rock (for example quartz, marble, or anite), small bbles, or other mineral b ies of suitable size and desired character and color. These arenow pressed into the block or brick to embed them therein, by any convenient means, as for example a plun or or presser-plate 36, actuated by any suita 1e means not shown. In this We surfaces of'a. great variety of kinds an I textures can be obtained, reproducing or closely simulating natural unpolished stone. If a facing layer 35' is also used it may be rich in cement so as to afford secure anchorage for the embedded particles, and may be colored to harmonize or contrast therewith as may be desirable. Another, way of accomplishing the same or a similar result is to mix the pebbles, crushed stone, or other particles, with the material with which the brick, or block, or other product is to be faced. In such case the rock particles exposed at the surface of the facing layer are apt to be coated, more or less, with a film of cement, but such film can be easily removed by a quick washing with a fine spray of water, or, if the material has set or hardened, with weak hydrochloric acid, leavin V the exposed faces pf particles clean an bright, like the surface of freshly broken stone, pebbles orpallet.

Still another way of giving a finish to the facing layer is to wipe or beat the surface with a brush of suitable stifl'ness. Wiping,

or drawing the brush over the plastic surface, gives a graining effect, straighter wavy, and beating or pounding with the brush gives a rough texture resembling sandstone or other desired face-textures or finishes.

If a smooth, polished, or glazed efi'ect is desired a pallet having a polished surface is used, for example a pallet made of, or provided with a layer or plate of, glass, celluloid, polished metal, or other suitable material, which imparts a correspondingsurface to the facing layer formed thereon.

This is particularly desirable where the facing is composed of white cement and contains fine white sand or crushed white marhis.

(As before stated, the material of the facing layer or layers may be of widely varying character or consistency or both, depending largely upon the purpose for which the bricks, or other products, are to be used.

For example, the facing may be of the same (ill composition as the body of the block, but different in color, or it may be richer in cement so as to give a finer grain or smoother or harder surface or it may contain an ingredient intended to make the layer water-proof or less absorbent. In general I prefer to have the facing material wet, that is, containing at least enough water, if not more than enough. for complete hydration. In many cases the facing can be relatively thin, for example about an eighth of an inch thick, inasmuch as the layer is firmly joined to the underlying body of concrete and is, in fact, practically integral therewith.

It is to be understood that the invention is not limited to the features herein specifi- '.all v described but can be practised in other 'ays without departure from its spirit as defined by the following claims. i

I claim:

1. In' the art of making faced cementitious products or articles, the improvement comprising; establishing and maintaining a column of slush concrete of a height enabling the weight of the column to compact and unwater the lower portion of the column. applying a facing layer of cementitious material to the lower portion of the column and utilizing the weight of the column to compact said material and unite it with the column, and shaping a self-sustaining, faced, and unset cementitious article from such lower portion.

2. In the art of making faced cementitious products or articles, the improvement comprising establishing and maintaining a column of slush concrete of a height enabling the weight of the column to compact and unwatcr its lower portion, applying a facing layer of cementitious material to the lower portion of the column, and passing a knife of substantial thickness into the lower portion of the column to sever the lower portion of the column and simultaneously compact the same.

3. In the-art of making faced cementitious products or articles, the improvement comprising establishing and maintaining a column of slush concrete of a height enabling the weight of the column to compact and unwatcr its lower portion, arranging under the column a suitably supported layer of cemcntitious facing material, allowing lhc column to descend upon the layer of facing material whereby said layer is com, pactcd and united with the underside of the column. and shaping a faced, self-sustaining. unset ccmcntitious article from said lower portion.

-l. In the art of making faced cementitious products or articles, the improvement comprising establishing and maintaining a column of slush concrete of a height enabling the weight of the column to compact and u'nwater itslower portion, arranging under the column a suitably supported layer of cementitious facing material, allowing the column to fall suddenly upon such layer whereby the same is subjected to the impact of the column and is compacted and unwatered and integrally united with the column, and shaping a faced, self-sustain ing, unset cementitious article from said lower portion.

In the art of making faced cementitious products or articles, the improvement comprising establishing and maintaining a column of.slush concrete of a height enabling the weight of the column to compact and nnwater its lower portion, applying to the lower portion of the column a 'ing layer of cementitious material and.

utilizing the weight of the column to compact and join to its lower portion said facing layer, severing the lower portion of the column, and cutting through the severed portion and the facing material thereon to form a plurality of faced articles.

6. In the art of making faced cementitious products or articles, the improvement comprising establishing and maintaining a column of slush concrete of such height that the weight of the column will compact and unwater its lower portion, applying cementitious facing material to the lower portion of the column and causing the weight of the column itself to compact the facing material and unite the same with the column, severing the now faced lower portion of the column, and cutting up such severed portion into articles each having a facing on at least one surface.

7. In the art of making faced cementitious products or articles, the improvement comprising establishing and maintaining a column of slush concrete of a height enabling the weight of the column to compact and unwater its lower portion, applying a facing layer of cementitious material to the lower portion of the column and utilizing the weight of the column to compact such layer and unite it with said lower portion. and passing a horizontal knife-and one or more vertical knives into the lower portion of the column to sever the faced lower portion and divide the same into a plurality of faced, unset, self-sustaining articles.

8. In the art of making faced. cementitious products or articles, the improvement comprising establishing and maintaining a column of slush concrete of such height that the weight of the column will compact and unwatcr its lower portion, arranging below the column ,a pallet carrying on its upper surface a. relatively thin body of cementitious facing material of substantially the same area as the bottom of the column. allowing the column to descend suddenly upon 'said relatively thin body of facing material whereby the same is subjected to the impact of the column and is thereby compacted and united with the column. and carving one or more fa ed. self-sustainiiw. unset articles from the compacted and unwatered lowerportion of the column. 4

9. in the art of lnaltin; faced cementitious products'or articles. the improvement comprising establishine and maintaininp acolumn of slush concrete of a height eneblin; its own weight to compact and unwater its lower portion. applyin; a facing layer of cen.-cntitious material to the lower portion of the column and utilizin; the weight of the column to compact said layer and unite the same with the said lower portion. shaping from the faced lower portion of the column a faced unset self sustaining article, spreadine solid particles of the kind described upon the unset facin; on said article, and pressing: the solid particles into said facing to embed them therein.

10. In the art of making faced cementitious products or articles. the improvement comprising: establishing: and maintaining a column of slush concrete of a height enabling the weight of the column to compact and unwater its lower portion, applying a facing layer of cementitious material to the lower part of the column and utilizing the weight of the column to compact said layer and unite the same with said lower portion,

and unset concrete. causinc said body to descend upon and unite to itself a facing; layer of cementitious material. shaping from the faced lower portion of said body a faced unset self-sustaining. article. and embedding particles of the kind described in a surface of said article.

l2. ln'the art of making faced cementitious products 'or articles. the improvement tomprising forming! and maintaining an upright body of wet. compacted. unwatered and unset concrete. causing said body to descend upon and unite to itself a facing, layer of .ementitious material. shaping from the faced lower portion of said body a faced, unset. self-sustaining article, inclosing said article in a lateral support. spreading upon the unset facing: a layer of solid particles of the kind described, and exerting pressure upon the layer of solid particles to embedthe latter in said facin In testimony whereof I affix my signature.

ALFRED OWEN CROZIER.

a faced unset self-sustaining article 

